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NASA NTRS2016

Hydrogen Purification and Recycling for an Integrated Oxygen Recovery System Architecture

The United States Atmosphere Revitalization life support system on the International Space Station (ISS) performs several services for the crew including oxygen generation, trace contaminant control, carbon dioxide (CO2) removal, and oxygen recovery. Oxygen recovery is performed using a Sabatier reactor developed by Hamilton Sundstrand, wherein CO2 is reduced with hydrogen in a catalytic reactor to produce methane and water. The water product is purified in the Water Purification Assembly and recycled to the Oxygen Generation Assembly (OGA) to provide O2 to the crew. This architecture results in a theoretical maximum oxygen recovery from CO2 of approximately 54% due to the loss of reactant hydrogen in Sabatier-produced methane that is currently vented outside of ISS. Plasma Methane Pyrolysis technology (PPA), developed by Umpqua Research Company, provides the capability to further close the Atmosphere Revitalization oxygen loop by recovering hydrogen from Sabatier-produced methane. A key aspect of this technology approach is to purify the hydrogen from the PPA product stream which includes acetylene, unreacted methane and byproduct water and carbon monoxide. In 2015, four sub-scale hydrogen separation systems were delivered to NASA for evaluation. These included two electrolysis single-cell hydrogen purification cell stacks developed by Sustainable Innovations, LLC, a sorbent-based hydrogen purification unit using microwave power for sorbent regeneration developed by Umpqua Research Company, and a LaNi4.6Sn0.4 metal hydride produced by Hydrogen Consultants, Inc. Here we report the results of these evaluations, discuss potential architecture options, and propose future work.

Abney, Morgan B.↗
NASA NTRS2007

Simulation of Unique Pressure Changing Steps and Situations in Psa Processes

A more rigorous cyclic adsorption process simulator is being developed for use in the development and understanding of new and existing PSA processes. Unique features of this new version of the simulator that Ritter and co-workers have been developing for the past decade or so include: multiple absorbent layers in each bed, pressure drop in the column, valves for entering and exiting flows and predicting real-time pressurization and depressurization rates, ability to account for choked flow conditions, ability to pressurize and depressurize simultaneously from both ends of the columns, ability to equalize between multiple pairs of columns, ability to equalize simultaneously from both ends of pairs of columns, and ability to handle very large pressure ratios and hence velocities associated with deep vacuum systems. These changes to the simulator now provide for unique opportunities to study the effects of novel pressure changing steps and extreme process conditions on the performance of virtually any commercial or developmental PSA process. This presentation will provide an overview of the cyclic adsorption process simulator equations and algorithms used in the new adaptation. It will focus primarily on the novel pressure changing steps and their effects on the performance of a PSA system that epitomizes the extremes of PSA process design and operation. This PSA process is a sorbent-based atmosphere revitalization (SBAR) system that NASA is developing for new manned exploration vehicles. This SBAR system consists of a 2-bed 3-step 3-layer system that operates between atmospheric pressure and the vacuum of space, evacuates from both ends of the column simultaneously, experiences choked flow conditions during pressure changing steps, and experiences a continuously changing feed composition, as it removes metabolic CO2 and H20 from a closed and fixed volume, i.e., the spacecraft cabin. Important process performance indicators of this SBAR system are size, and the corresponding CO2 and H20 removal efficiencies, and N2 and O2 loss rates. Results of the fundamental behavior of this PSA process during extreme operating conditions will be presented and discussed.

Ebner, Armin D.↗
NASA NTRS2014

Evaluating the Adsorptive Capabilites of Chemsorb 1000 and Chemsorb 1425

The removal of trace contaminants from spacecraft cabin air is necessary for crew health and comfort during long duration space exploration missions. The air revitalization technologies used in these future exploration missions will evolve from current ISS ISS State-of-Art (SOA) and is being designed and tested by the Advanced Exploration Systems (AES) Program's Atmosphere Resource Recovery and Environmental Monitoring (ARREM) project. The ARREM project is working to mature optimum atmosphere revitalization and environmental monitoring system architectures to enable exploration beyond Lower Earth Orbit (LEO). The Air Revitalization Lab at KSC is one of six NASA field centers participating in the ARREM that specializes in adsorbent and catalyst characterization with simulated spacecraft gas streams using combinations of pressure, O2 partial pressure, CO2 partial pressure, and humidity that are representative of a range of anticipated cabin atmospheric conditions and loads. On board ISS, the Trace Contaminant Control Subassembly (TCCS) provides active control of trace contaminants from the cabin atmosphere utilizing physical adsorption, thermal catalytic oxidation, and chemical adsorption processes. High molecular weight contaminants and ammonia (NH3) are removed a granular activated carbon treated with approx. 10% by weight phosphoric acid (H3PO4) (B-S Type 3032 4×6 mesh), which is expendable and is periodically refurbished. The Type 3032 granular activated carbon bed is no longer commercially available and therefore it is important to characterize the efficiency and capacity of commercially available NH3 sorbents. This paper describes the characterization of two Molecular Products LTD activated carbons: Chemsorb 1000 and Chemsorb 1425. Untreated activated carbons (e.g. Chemsorb 1000) remove contaminants by physisorption, which concentrates the contaminant within the pores of the carbon while letting air to pass through the sorbent4. Low molecular weight or polar gases (e.g. HCl, SO2, formaldehyde, and NH3) are not removed by physisorption and typically require chemisorption for removal. Treated activated carbons (e.g. Chemsorb 1425) are impregnated with a a chemical agent (e.g. phosphoric acid) that reacts with those gases, converting them to solids or salts within the carbon and removes them from the air stream. This process occurs via neutralization or catalysis reactions and adsorption capacity is exhaustedwhen the available impregnated chemicals are consumed. Moisture affects removal performance since adsorption sites within the pores are filled with water. The performance of impregnated carbons may be enhanced by moisture content because the mechanisms of contaminant removal are chemical reactions that occur in reagents contained within the pores. The adsorptive capacity data (mol/kg) of Chemsorb 1000 and 1425 for gas mixtures (ethanol, acetone, toluene, acetaldehyde, dichloromethane, and xylene) was measured with 40% relative humidity at 23 deg C air temperature. The adsorptive capacity data (mol/kg) of Chemsorb 1425 was measured using NH3 gas streams.

adsorptive capacities↗
NASA NTRS2012

Integrated Atmosphere Resource Recovery and Environmental Monitoring Technology Demonstration for Deep Space Exploration

Exploring the frontiers of deep space continues to be defined by the technological challenges presented by safely transporting a crew to and from destinations of scientific interest. Living and working on that frontier requires highly reliable and efficient life support systems that employ robust, proven process technologies. The International Space Station (ISS), including its environmental control and life support (ECLS) system, is the platform from which humanity's deep space exploration missions begin. The ISS ECLS system Atmosphere Revitalization (AR) subsystem and environmental monitoring (EM) technical architecture aboard the ISS is evaluated as the starting basis for a developmental effort being conducted by the National Aeronautics and Space Administration (NASA) via the Advanced Exploration Systems (AES) Atmosphere Resource Recovery and Environmental Monitoring (ARREM) Project.. An evolutionary approach is employed by the ARREM project to address the strengths and weaknesses of the ISS AR subsystem and EM equipment, core technologies, and operational approaches to reduce developmental risk, improve functional reliability, and lower lifecycle costs of an ISS-derived subsystem architecture suitable for use for crewed deep space exploration missions. The most promising technical approaches to an ISS-derived subsystem design architecture that incorporates promising core process technology upgrades will be matured through a series of integrated tests and architectural trade studies encompassing expected exploration mission requirements and constraints.

Perry, Jay L.↗
NASA NTRS2011

A Comparison of Photocatalytic Oxidation Reactor Performance for Spacecraft Cabin Trace Contaminant Control Applications

Photocatalytic oxidation (PCO) is a maturing process technology that shows potential for spacecraft life support system application. Incorporating PCO into a spacecraft cabin atmosphere revitalization system requires an understanding of basic performance, particularly with regard to partial oxidation product production. Four PCO reactor design concepts have been evaluated for their effectiveness for mineralizing key trace volatile organic com-pounds (VOC) typically observed in crewed spacecraft cabin atmospheres. Mineralization efficiency and selectivity for partial oxidation products are compared for the reactor design concepts. The role of PCO in a spacecraft s life support system architecture is discussed.

Perry, Jay L.↗
NASA NTRS1973

Space Shuttle Orbiter ECLSS.

The Orbiter Environmental Control and Life Support System (ECLSS) provides the functions of atmosphere revitalization, crew life support, active thermal conditioning, and airlock support for EVA and docking activities. The ECLSS must satisfy the requirements of orbital missions with four to ten crewmembers and mission duration of a few hours to 30 days and the requirements associated with an atmospheric horizontal flight test program and ferry flight missions. The ECLSS development plan utilizes an ECLSS ground test article and thermal/vacuum testing to support the first horizontal flight test at the end of 1976. The ground testing and horizontal flight test program certify the Orbiter ECLSS for the first orbital flight in early 1978.

Stoll, O. T.↗
NASA NTRS2014

Amine Swingbed Payload Testing on ISS

One of NASA Johnson Space Center's test articles of the amine-based carbon dioxide (CO2) and water vapor sorbent system known as the CO2 And Moisture Removal Amine Swing-bed, or CAMRAS, was incorporated into a payload on the International Space Station (ISS). The intent of the payload is to demonstrate the spacecraft-environment viability of the core atmosphere revitalization technology baselined for the new Orion vehicle. In addition to the air blower, vacuum connection, and controls needed to run the CAMRAS, the payload incorporates a suite of sensors for scientific data gathering, a water save function, and an air save function. The water save function minimizes the atmospheric water vapor reaching the CAMRAS unit, thereby reducing ISS water losses that are otherwise acceptable, and even desirable, in the Orion environment. The air save function captures about half of the ullage air that would normally be vented overboard every time the cabin air-adsorbing and space vacuum-desorbing CAMRAS beds swap functions. The JSC team conducted 1000 hours of on-orbit Amine Swingbed Payload testing in 2013 and early 2014. This paper presents the basics of the payload's design and history, as well as a summary of the test results, including comparisons with prelaunch testing.

Button, Amy B.↗
NASA NTRS2014

Amine Swingbed Payload Testing on ISS

One of NASA/Johnson Space Center's test articles of the amine-based carbon dioxide (CO2) and water vapor sorbent system known as the CO2 And Moisture Removal Amine Swing-bed, or CAMRAS, was incorporated into a payload on the International Space Station (ISS). The intent of the payload is to demonstrate the spacecraft-environment viability of the core atmosphere revitalization technology baselined for the new Orion vehicle. In addition to the air blower, vacuum connection, and controls needed to run the CAMRAS itself, the payload incorporates a suite of sensors for scientific data gathering, a water save function, and an air save function. The water save function minimizes the atmospheric water vapor reaching the CAMRAS unit, thereby reducing ISS water losses that are otherwise acceptable, and even desirable, in the Orion environment. The air save function captures about half of the ullage air that would normally be vented overboard every time the cabin air-adsorbing and space vacuum-desorbing CAMRAS beds swap functions. The JSC team conducted 1000 hours of on-orbit Amine Swingbed Payload testing in 2013. This paper presents the basics of the payload's design and history, as well as a summary of the test results, including comparisons with prelaunch testing.

Button, Amy↗
NASA NTRS1974

Environmental control system development for manned spacecraft 1960-1973

This paper provides an overview of the development of environmental revitalization techniques from their beginnings in caisson and submarine habitats, up to the present time. The use of CO2 adsorbents, such as LiOH and their application to the first U.S. manned spaceflight is described, together with the beginnings of the regenerable CO2 sorber technology using molecular sieves and its ultimate application to Skylab. The concepts and hardware systems used for atmospheric revitalization on all major U.S. ground-based manned tests is detailed, including CO2 reduction and O2 generation processes. Current research and development efforts are also outlined. The paper concludes with a detailed description of the recently completed SSP, the most advanced and complete ECS that has been fabricated to date.

Popma, D. C.↗
NASA NTRS2014

CO2 Reduction Assembly Prototype Using Microlith-Based Sabatier Reactor for Ground Demonstration

The utilization of CO2 to produce life support consumables, such as O2 and H2O, via the Sabatier reaction is an important aspect of NASA's cabin Atmosphere Revitalization System (ARS) and In-Situ Resource Utilization (ISRU) architectures for both low-earth orbit and long-term manned space missions. Carbon dioxide can be reacted with H2, obtained from the electrolysis of water, via Sabatier reaction to produce methane and H2O. Methane can be stored and utilized as propellant while H2O can be either stored or electrolyzed to produce oxygen and regain the hydrogen atoms. Depending on the application, O2 can be used to replenish the atmosphere in human-crewed missions or as an oxidant for robotic and return missions. Precision Combustion, Inc. (PCI), with support from NASA, has previously developed an efficient and compact Sabatier reactor based on its Microlith® catalytic technology and demonstrated the capability to achieve high CO2 conversion and CH4 selectivity (i.e., ≥90% of the thermodynamic equilibrium values) at high space velocities and low operating temperatures. This was made possible through the use of high-heat-transfer and high-surface-area Microlith catalytic substrates. Using this Sabatier reactor, PCI designed, developed, and demonstrated a stand-alone CO2 Reduction Assembly (CRA) test system for ground demonstration and performance validation. The Sabatier reactor was integrated with the necessary balance-of-plant components and controls system, allowing an automated, single "push-button" start-up and shutdown. Additionally, the versatility of the test system prototype was demonstrated by operating it under H2-rich (H2/CO2 of >4), stoichiometric (ratio of 4), and CO2-rich conditions (ratio of <4) without affecting its performance and meeting the equilibrium-predicted water recovery rates. In this paper, the development of the CRA test system for ground demonstration will be discussed. Additionally, the performance results from testing the system at various operating conditions and the results from durability testing will be presented.

Junaedi, Christian↗
NASA NTRS2015

Thirsty Walls: A New Paradigm for Air Revitalization in Life Support

Carbon Dioxide removal systems on submarines are compact and reliable. They use solubility chemistry. They spray a Carbon Dioxide adsorbing chemical directly into the air stream, and allow the liquid to settle. Carbon Dioxide removal systems on ISS are large and need repair. They use adsorption chemistry. They force air through a bed packed with granular zeolite, and heat the bed to desorb the Carbon Dioxide. The thermal cycles cause the zeolite to dust. New advances in additive manufacturing, and a better understanding of uid behavior in microgravity make it possible to expose a liquid directly to air in a microgravity environment. It is now practical to use submarine style solubility chemistry for atmosphere revitalization in space. It is now possible to develop space systems that achieve submarine levels of reliability. New developments in Ionic Liquid research make it possible to match the solubility performance characteristics of MEA used on submarines - with Ionic Liquids that do not release chemical vapors into the air. "Thirsty Walls" provide gentle, passive contact between ventilation air and Air Revitalization functions of temperature control, relative humidity control, and Carbon Dioxide removal. "Thirsty Walls" eliminates the need of large blowers and compressors that need to force air at high velocities through restrictive Air Revitalization hardware.

Graf, John↗
NASA NTRS2010

Planetary Protection Considerations for Life Support and Habitation Systems

Life support systems for future human missions beyond low Earth orbit may include a combination of existing hardware components and advanced technologies. Discipline areas for technology development include atmosphere revitalization, water recovery, solid waste management, crew accommodations, food production, thermal systems, environmental monitoring, fire protection and radiation protection. Life support systems will be influenced by in situ resource utilization (ISRU), crew mobility and the degree of extravehicular activity. Planetary protection represents an additional set of requirements that technology developers have generally not considered. Planetary protection guidelines will affect the kind of operations, processes, and functions that can take place during future exploration missions, including venting and discharge of liquids and solids, ejection of wastes, use of ISRU, requirements for cabin atmospheric trace contaminant concentrations, cabin leakage and restrictions on what materials, organisms, and technologies that may be brought on missions. Compliance with planetary protection requirements may drive development of new capabilities or processes (e.g. in situ sterilization, waste containment, contaminant measurement) and limit or prohibit certain kinds of operations or processes (e.g. unfiltered venting). Ultimately, there will be an effect on mission costs, including the mission trade space. Planetary protection requirements need to be considered early in technology development programs. It is expected that planetary protection will have a major impact on technology selection for future missions.

Barta, Daniel J.↗
NASA NTRS2011

Compact and Lightweight Sabatier Reactor for Carbon Dioxide Reduction

The utilization of CO2 to produce life support consumables, such as O2 and H2O, via the Sabatier reaction is an important aspect of NASA s cabin Atmosphere Revitalization System and In-Situ Resource Utilization architectures for both low-earth orbit and long-term manned space missions. In the current International Space Station (ISS) and other low orbit missions, metabolically-generated CO2 is removed from the cabin air and vented into space, resulting in a net loss of O2. This requires a continuous resupply of O2 via water electrolysis, and thus highlights the need for large water storage capacity. For long-duration space missions, the amount of life support consumables is limited and resupply options are practically nonexistent, thus atmosphere resource management and recycle becomes crucial to significantly reduce necessary O2 and H2O storage. Additionally, the potential use of the Martian CO2-rich atmosphere and Lunar regolith to generate life support consumables and propellant fuels is of interest to NASA. Precision Combustion, Inc. (PCI) has developed a compact, lightweight Microlith(Registered TradeMark)-based Sabatier (CO2 methanation) reactor which demonstrates the capability of achieving high CO2 conversion and near 100% CH4 selectivity at space velocities of 30,000-60,000 hr-1. The combination of the Microlith(Registered TradeMark) substrates and durable, novel catalyst coating permitted efficient Sabatier reactor operation that favors high reactant conversion, high selectivity, and long-term durability. This paper presents the reactor development and performance results at various operating conditions. Additionally, results from 100-hr durability tests and mechanical vibration tests are discussed.

Junaedi, Christian↗
NASA NTRS1992

Evaluation of the carbon dioxide removal assembly requirements for the Space Station Freedom in the Manned Tended Capability through Permanently Manned Capability configurations

Analyses have been conducted to assess the capability of the Atmosphere Revitalization Subsystem to control ambient CO2 levels of the Space Station Freedom (SSF). The adequacy of the Carbon Dioxide Removal Assembly (CDRA) performance to meet design requirements has been evaluated. Analyses considered transient effects of crew location and metabolic loading on SSF Restructure configurations. The analyses consisted of computer simulations of on-orbit conditions using both supplier-provided and adjusted CO2 removal performance approximations along with derived crew metabolic activities and locations. Results show that while the current performance of the CDRA will maintain CO2 levels within specifications for Man-Tended Operations, it cannot maintain the SSF atmosphere below specifications during Permanently Manned Operations. Potential design options are discussed and other relevant analyses are summarized.

Knox, J. C.↗
NASA NTRS1979

Radioisotope thermoelectric generator cooling in the Shuttle bay

The paper describes a Shuttle-integrated radioisotope thermoelectric generator (RTG) that consists primarily of a pump package and plumbing connected directly to the Shuttle payload heat exchanger. The RTG utilizes on-board water evaporative cooling capability, which is normally used for ascent, entry, and for supplementing the radiators. Attention is given to the RTG cooling concepts which include: (1) an active thermal cooling system (ATCS), where two Freon-21 loops operate simultaneously to transport heat from the Orbiter subsystem and payloads through liquid-to-liquid heat exchangers and pin-fin coldplates to four heat sinks, and (2) an atmosphere revitalization system (ARS) which provides for thermal, pressure, and contaminate control of the crew cabin and its equipment. The use of a payload heat exchanger to reduce weight, cost and complexity associated with an independent cooling system was investigated in detail.

Stimpson, L. D.↗
NASA NTRS1981

Space Shuttle life support systems - A status report

The Space Shuttle Program has two independent life support systems. One provides the basic environmental control for the Orbiter cabin while the second enables the crewmen to function outside the spacecraft for extravehicular operation. Although both of these systems were developed and fabricated under contract to NASA, all system-level testing was conducted at the Johnson Space Center. The paper will discuss the results of this testing which, in part, includes: (1) certification of the Orbiter cabin atmospheric pressure and composition control system at three operational pressures (8 psia, 9 psia and 14.7 psia); (2) certification of the Orbiter atmospheric revitalization system at 9 psia and 14.7 psia; (3) manrating of the Orbiter airlock at 14.7 psia, 9 psia and vacuum; and (4) certification of the space suit/life support system in the airlock and at deep space thermal/vacuum conditions. In addition, pertinent flight information from the on-orbit performance of the Shuttle life support systems will be presented.

Faget, M. A.↗
NASA NTRS1983

Toxicological evaluation of the Columbia spacecraft

The toxicology procedures developed for the Space Shuttle program to evaluate and eliminate contaminants in the cabin atmosphere characterized, and results from STS missions 1-5 are reviewed. Shuttle maximum-allowable-concentration standards (SMAC) equal to 10-50 percent of those established for normal 40-h work weeks on the ground have been established for a broad range of substances, and outgassing data are employed in choosing spacecraft construction materials. Gases are removed by the atmospheric revitalization system (CO2-removal bed, catalytic oxidizer, and dehumidifier). Whole-gas and adsorbed-gas samples are employed in ground-based and inflight measurements of contaminants: results are presented in tables. A total of 152 substances, of which 64 were well defined, were detected in STS-1-5. Only the toluene contamination on STS-2 (17 ppm compared to the SMAC of 20 ppm) was considered serious.

Rippstein, W. J., Jr.↗
NASA NTRS1984

Environmental control and life support system analysis tools for the Space Station era

This paper describes the concept of a developing emulation, simulation, sizing, and technology assessment program (ESSTAP) which can be used effectively for the various functional disciplines (structures, power, ECLSS, etc.) beginning with the initial system selection and conceptual design processes and continuing on through the mission operation and growth phases of the Space Station for the purpose of minimizing overall program costs. It will discuss the basic requirements for these tools, as currently envisioned for the Environmental Control and Life Support System (ECLSS), identifying their intended and potential uses and applications, and present examples and status of several representative tools. The development and applications of a Space Station Atmospheric Revitalization Subsystem (ARS) demonstration model to be used for concent verification will also be discussed.

Blakely, R. L.↗